Volkswagen Transporter T4 Manuallines Download Page 1

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Body builder guidelines 20

Body builder guidelines
Transporter T4

Summary of Contents for Transporter T4

Page 1: ...Body builder guidelines 2007 Body builder guidelines Transporter T4...

Page 2: ...horised testing centre for approval It is recommended to clarify in advance with the relevant authority whether approval is required When inquiring about planned modifications please enclose two sets...

Page 3: ...vided by Volkswagen AG is subject to the reservation that modified vehicles are not tested by Volkswagen AG Modifications may affect the properties of the vehicle For reasons of liability the body bui...

Page 4: ...gressive media e g bird droppings industrial dusts and clean if required Check battery open circuit voltage every three months Open circuit voltage means the voltage of the disconnected battery after...

Page 5: ...and preparations The vehicle owner must keep all assembly documentation concerning the modification and hand them over together with the vehicle to the dismantler This ensures that modified vehicles...

Page 6: ...ing tightening torques settings and tolerances as well as other relevant specifications Special tools including their source of supply must also be stated The manual must also state which type of work...

Page 7: ...must be observed The body builder or device or equipment manufacturer is responsible for the compliance with these laws rules and regulations For further information about commercial freight traffic...

Page 8: ...kg details 2 1 Dimensions and Weight Large proportion of usable floor area Hatch clearance width between the wheel housings 122 cm pallet dimensions Low plane loading floor with a height of 52 cm Sta...

Page 9: ...ote Subject to errors and technical amendments The electronic version of the body guidelines is the decisive source of up to date data on body guidelines online body guidelines Data status March 2009...

Page 10: ...ight of the entire vehicle is to be determined using a scale Petrol diesel 4 cylinders Petrol diesel 5 cylinders 5 cylinders TDI VR 6 petrol engine Petrol diesel 4 cylinders Name PR No Wheelbase Permi...

Page 11: ...105 Chassis with driver s cab 0J3 2 920 2 785 1 330 1 490 1 375 1 015 360 1 410 Chassis with driver s cab 0J2 3 320 2 575 1 330 1 410 1 400 1 030 370 1 175 Chassis with driver s cab 0J3 3 320 2 785 1...

Page 12: ...1 330 1 682 1 110 572 1 018 Station wagon 0J3 2 920 2 800 1 480 1 490 1 682 1 110 572 1 118 Station wagon1 0J2 2 920 2 620 1 400 1 230 1 682 1 110 572 938 Station wagon 0J2 3 320 2 700 1 570 1 330 1 7...

Page 13: ...R No 1P4 is set deeper by 20 mm 2 Unladen weight with trim panel in the passenger compartment boot space Trim panel controllable with PR No 5DA New Latest unladen weight including driver s weight but...

Page 14: ...truck 0J3 3 320 2 800 1 510 1 490 1 635 1 160 525 1 115 Flatbed truck 0J5 1LE 3 320 2 890 1 510 1 490 1 635 1 160 525 1 205 Deep loading flatbed truck 0J2 3 320 2 680 1 430 1 410 1 685 1 165 520 995...

Page 15: ...n weight including driver s weight but without seats in the passenger compartment Only for camper vans and sales vehicles Important notice For vehicles with automatic gear the unladen weight is increa...

Page 16: ...aximum difference between the wheel loads of 4 Example Permitted axle load 1 430 kg Theoretical wheel load left right 715 kg 715 kg 4 of this wheel load 29 kg Permitted wheel load distribution left ri...

Page 17: ...of the wheel base The maximum permitted overhang rear of 40 of the wheel base results in the following max external attachment lengths for chassis These values must not be exceeded Wheelbase Standard...

Page 18: ...Jede Konsole ist mit einer Bohrung von 11 mm versehen Die Befestigung zwischen Aufbau und Fahrzeugrahmen sollte immer ber alle Konsolen erfolgen Die Schraubverbindung zu den Konsolen mu kraftschl ssig...

Page 19: ...p up top 50 kg Rear luggage carriers rear ladders The rear luggage carrier or the rear ladder must be executed in such a way that after having been mounted no vertical static or dynamic loads are work...

Page 20: ...ly available hatchback lid hinge version the air gap between roof and opened tailboard was considerably reduced To prevent the top holding clamps of the rear luggage carrier from pressing onto the roo...

Page 21: ...not in combination with a sliding door and or seats in the passenger compartment In this case the sliding door opening of the right sliding door is only 680 mm instead of 1020 mm Long wheel base gener...

Page 22: ...in connection which is reconnected when the vehicle is to be transferred respectively by the delivery service If the vehicles are parked at attachment manufacturers for a longer time shutdown period i...

Page 23: ...n 2nd Generator Bosch 14 V 90 A 2 0l 62 kW petrol engine R 4 x 2 0l 62 kW petrol engine R 4 with catalytic converter x 2 5l 81 kW petrol engine R 5 with catalytic converter x x 2 8l 103 kW petrol engi...

Page 24: ...ecial cases for example retrofitting of reinforced springs mounting of an unusually lightweight attachment it is required to correct the regulation of the brake proportioning valve The pressure check...

Page 25: ...103 129 108 135 For deviating axle loads intermediate values are to be applied For adjustment and function refer to the operating instructions Note Subject to errors and technical amendments The elec...

Page 26: ...1Nm With the specified axle loads every pressure within the tolerance limits is permitted e g 600 630 kg 4 7 bar General note We recommend that the attachment manufacturers equipment suppliers add ap...

Page 27: ...hments upgrades according to the specifications of our attachment guidelines d 2 Boundary conditions 2 1 The maximum permitted axle loads correspond to those of PR Nr 0J3 2 2 Closed attachments box ty...

Page 28: ...d a A positive test result from our development department b If an import certificate is already available for an upgrading modification variant please enclose a copy when requesting a further import...

Page 29: ...s the minimum distance between the top edge of the side rails and the wheel housings is indicated Note Subject to errors and technical amendments The electronic version of the body guidelines is the d...

Page 30: ...s on which also distance bushes are to be welded Note General instructions on chassis modifications Drilling at the chassis frame If attachments are to be added or to be installed it is required to ad...

Page 31: ...engine When projecting the loading crane attachments the required stability of the loading crane is to be considered As a result of the load distribution calculation to be performed flatbed modificat...

Page 32: ...ssible to attach a swinging lift with a load carrying capacity of max 300 kg When ordering a chassis which is to be equipped with an electrohydraulic loading tailboard we recommend the following optio...

Page 33: ...freedom of operation of the trailer behind the tractive unit is maintained DIN 74058 The standard radiator and fan has to be replaced by reinforced variants according to PR No 1D7 The vehicle has to b...

Page 34: ...te Subject to errors and technical amendments The electronic version of the body guidelines is the decisive source of up to date data on body guidelines online body guidelines Data status August 2007...

Page 35: ...p Adjustment a Determination of the axle load in unladen condition at the front without driver and with empty tank on the ready vehicle b The vehicle must be perfectly aligned deflected several times...

Page 36: ...200 kg 265 mm Dimension a is to be measured between the screw head of the damper reception above and the screw centre of the screw damper below If required the prescribed standing height can be adjust...

Page 37: ...evant platform location points Notes on the jack selection manufactured height max lift are to be taken from our separately available marketing information Standard lifting jack for standard chassis p...

Page 38: ...manufacturers is to be determined by the attachment manufacturers b The maximum permitted axle load for transporter chassis can be found under the specifications for the variant with a permitted total...

Page 39: ...ous frame which is to be connected force locking with the bordering supporting parts Retrofitting of windows If windows are to be retrofitted the following operation method can be implemented 1 Cut ou...

Page 40: ...te Subject to errors and technical amendments The electronic version of the body guidelines is the decisive source of up to date data on body guidelines online body guidelines Data status August 2007...

Page 41: ...below 2 Roof cut outs between bows B and C are only permitted at wheel base 2 920 mm Details on the max possible roof cut out permitted in this situation see section 3 3 Modification of closed attach...

Page 42: ...3 Large roof cut outs for normal roof versions and both wheel bases to retrofit high roofs and pop up tops Only for vehicles with max sliding door 41...

Page 43: ...sectional view B B Schnitt A A 90 gedreht Schnitt B B Cutting plane line in the cab area starting at front edge of B bow according to the above drawing specifications The continuously running cutting...

Page 44: ...If other roof frame reinforcement sets i e not the one from Westfalia co are to be used it has to be ensured that the moment of resistance corresponds to that of the Westfalia set 2 Optionally it is a...

Page 45: ...loor is required it is also permitted to use a water tight chipboard This chipboard has then to screwed in or glued in flatly 3 Design of the High Roof a Wheel base 2 920 mm The high roof shell must c...

Page 46: ...te Subject to errors and technical amendments The electronic version of the body guidelines is the decisive source of up to date data on body guidelines online body guidelines Data status August 2007...

Page 47: ...or PR No 6B0 concerns only the home market for exports add option b If seats are missing in the passenger compartment the heater core will also be missing there the so called 2nd heater core In additi...

Page 48: ...nting points of the seats The triple seat variants must not be raised In this case it is required to cut out the seat mounting area appropriately Procedure with illustration part numbers etc available...

Page 49: ...a The load of vehicles whose load was already reduced net load class PR No 0J1 cannot be increased anymore b The vibration shock absorbers front rear are identical for all three net load classes Pr N...

Page 50: ...housings at the back and ballast weight PR No 2 A1 The wheel housings are suitable for permanent usage Note Subject to errors and technical amendments The electronic version of the body guidelines is...

Page 51: ...be realised form locking i e elastically This means that the connection must not be force locking Instead the connection has to be realised in such a way that the occurring torsions between boot and c...

Page 52: ...In addition these boreholes must not be used for holding any instruments modules etc Boreholes for connecting passages for pipes electric cables tackle blocks etc and for attaching add on parts clamp...

Page 53: ...l must not be removed without being replaced by an adequate component A possibility for a transfer according to ENT 149918 is represented below Connections between boot attachments and double cab must...

Page 54: ...ion of chassis with double cab pressure struts for the safety belts according to ENT 149 918 Required for usage for the standard trailing link arms if these must be removed for installing special atta...

Page 55: ...te Subject to errors and technical amendments The electronic version of the body guidelines is the decisive source of up to date data on body guidelines online body guidelines Data status August 2007...

Page 56: ...r welding In exceptional cases also well drained stick electrodes 2 5 mm with lime basic coating may be used If additional brackets etc are welded it is only permitted to weld in the so called neutral...

Page 57: ...hts axle loads rear overhangs depending on the wheel base etc are to be observed For this purpose adhere to the sections Dimensions and Weight Frame of the chassis extended Side view Note Subject to e...

Page 58: ...used for directly receiving auxiliary units etc Only screws are permitted for attaching the mounting frame at the chassis frame The mounting frame needs not to cover the entire chassis frame as is the...

Page 59: ...te Subject to errors and technical amendments The electronic version of the body guidelines is the decisive source of up to date data on body guidelines online body guidelines Data status August 2007...

Page 60: ...BB Box type station OJ1 OJ2 S 757 858 1140 Flatbed double cab OJ2 S 688 850 1180 Chassis OJ2 S 654 850 1160 Box type station OJ3 S 757 850 1185 Flatbed double cab OJ3 S 688 850 1120 Chassis OJ3 S 654...

Page 61: ...in the adjacent table always refer to the vehicle being loaded up to its respective permitted total weight Note Subject to errors and technical amendments The electronic version of the body guidelines...

Page 62: ...al attachments Chassis with driver s cab double cab Structural dimension drawing for special attachments Wheelbase 2 920 mm 2 920 mm 3 320 mm JPG Z Nr V03 773 010 372 kB Z Nr 707 000 011 527 kB Z Nr 7...

Page 63: ...Box type delivery van short wheelbase A1m Box type delivery van long wheelbase H1m 62...

Page 64: ...High space box type delivery van long wheelbase H1HDm Chassis with driver s cab short wheelbase E1m 63...

Page 65: ...assis with double cab long wheelbase M1m Note Subject to errors and technical amendments The electronic version of the body guidelines is the decisive source of up to date data on body guidelines onli...

Page 66: ...bject to modifications Edition November 2007 Internet www volkswagen nutzfahrzeuge de Consulting for body builders in Germany is available from the listed address Volkswagen Commercial Vehicles Brieff...

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